Method of producing cross-linked, unsaturated polyesters

ABSTRACT

A method of producing cross-linked unsaturated polyesters from a solution of a linear unsaturated polyester in a cross-linking agent, wherein a reaction medium comprising said solution and containing free hydroxyl radicals is brought in contact, at room temperature and under atmospheric pressure, with at least one hydrolyzable chlorine-containing derivative in an amount from 0.1 to 10% by weight, based on said solution.

This is a division of application Ser. No. 943,332 filed Sept. 18, 1978.

The present invention relates to a method of producing cross-linked,unsaturated polyesters and the application of this process to theproduction of filled foamed materials having high mechanicalcharacteristics and an excellent resistance to fire.

It is known that linear unsaturated polyesters may be cross-linked bybringing them in contact with cross-linking agents, for example vinylmonomers such as styrene, methyl methacrylate, vinyl toluene, triallylcyanurate, diallyl phthalate, or diisocynates (when the polyesters stillpresent free OH groups). Most often, in practice, the linear polyesteris marketed in the form of a solution in the cross-linking agent, andpolymerisation initiators and accelerators are added to initiate, thenmaintain, the cross-linking which causes gelation of the starting liquidmedium.

However, cross-linking takes place at a high speed, over a periodbetween a few seconds and a few minutes, only if the reaction occurs ata high temperature, this presenting numerous drawbacks in industrialproduction.

One object of the invention is to allow a very considerable accelerationof the cross-linking under the normal conditions of temperature andpressure.

According to the invention, there is provided a method of producingcross-linked unsaturated polyesters from a solution of a linearunsaturated polyester in a cross-linking agent, in which a reactionmedium comprising said solution and containing free hydroxyl radicals isbrought in contact, at room temperature and at atmospheric pressure,with at least one hydrolysable chlorine-containing derivative in anamount ranging from 0,1 to 10% by weight based on said solution.

Hydrolysis of the chlorine-containing derivative by the hydroxylradicals present in the medium is a strongly exothermic reaction and theheat thus produced raises the temperature of the reaction medium andthus provokes a strong acceleration of the cross-linking.

The OH radicals present in the reaction medium may have differentorigins. They may come from the unsaturated polyester itself, esterifiedincompletely, from the water present in adsorbed form in inert fillersintroduced in the reactional medium, or from the water present in freeform, added to the reaction medium.

The accleration of the gelation of the unsaturated polyesters providedby the invention considerably broadens the possibilities of use of thesepolyesters, as it makes it possible to obtain foamed products based onthese polyesters under excellent conditions.

The foaming step proceeds in fact very quickly and it is necessary toeffect it simultaneously with the cross-linking. In the case of theunsaturated polyesters, the duration of the cross-linking opposednitherto the production of foamed products. This difficulty is overcomeby the invention which precisely provides a considerable acceleration ofthe cross-linking.

There is also provided according to the invention a method ofmanufacturing foamed materials, wherein the reaction medium contains atleast one foaming agent.

This method is particularly advantageous as it starts from products oflow viscosity. This makes it possible to introduce in the reactionmedium mineral fillers of different types in a very high proportion.Filled foamed products are obtained having a real mineral skeleton, thedensity of which may reach 500 kg/m³ and which present an excellentcompressive strength of up to 100 kg/cm². Moreover, the cross-linkedunsaturated polyesters have, per se, a good thermal stability. Thefoamed products obtained will therefore have a superior fire resistanceand will advantageously be used as building materials. Thesecharacteristics make it possible, moreover, to produce homogeneoussandwich-panels by laminating pre-pregs of the same basic material,namely an unsaturated polyester, on blocks or plates of an alreadyfoamed and cross-linked material, or by applying on the walls of a moldtwo sheets of a non-cross-linked, reinforced, unsaturated polyester andby introducing the liquid to be foamed inside the mold.

A particularly advantageous embodiment consists in incorporating afinely divided carbonate in the reaction medium. The hydrolysis of thechlorine-containing derivatives gives rise to hydrochloric acide whichreacts with the carbonate to form carbon dioxide gas. The carbon dioxidegas acts as the foaming agent of the mixture.

On the other hand, the reaction products of the chlorides with thecarbonates are inert substances which serve as fillers in the finalfoamed product.

Starting materials 1. -Polymerisable mixture:

The starting linear unsaturated polyesters are obtained by more or lesscomplete esterification of acids, such as adipic acid, maleic acid,phthalic acid, by polyhydric alcohols such as glycols or hexanetriol.Ethyleneglycol polymaleatesphthalates are preferably used, with an OHvalue of between 30 and 250. The same polyesters may also be used, butin chlorinated or brominated form, this improving fire-proofing.

The chain length of these polyesters may vary. Short chain polyesterswill be chosen if rigid final products are desired, and long chainpolyesters will be chosen if more supple products are desired.

The cross-linking of these polyesters occurs by opening of their doublebonds and formation of cross-linkages under the action of cross-linkingagents such as vinyl monomers, particularly styrene, vinyltoluene,methyl methacrylate, diallyl phthalate, triallyl cyanurate, or thediisocyanates, when the polyesters still contain OH groups.

In practice, polyesters are marketed in the form of solution in thecross-linking agent, the mixture further containing polymerisationinhibitors such as quinone derivatives.

The proportion of the cross-linking agent in these mixtures is generallyfrom 20 to 30% by weight. Such mixtures are sold in particular under theTrademark SYNOLITE by Synres, Netherlands, under the Trademark STRATYLby Rhone-Poulenc, France, or under the Trademark HETRON by HookerChemical Company, United States of America.

To start polymerisation, which causes a gelation of the starting liquidmixture, polymerisation initiators are added, particularly organicperoxides (benzoyl peroxide, methylethyl ketone) and accelerators suchas paratoluidine or cobalt octoate.

II.- Chlorine-containing derivatives

A hydrolysable chlorine-containing derivative is suitably selected amongphosphorus trichloride PCl₃, phosphorus oxychloride POCl₃, phosphoruspentachloride PCl₅, boron chloride BCl₃, silicon chloride SiCl₄, or anacide chloride, particularly acetyl chloride or benzoyl chloride.

All these chlorine-containing derivatives are totally hydrolysed with aconsiderable production of heat.

The amount of these chlorine-containing derivatives is between 0,1 and10%, based on the polyester.

The mineral chlorine-containing derivatives are highly reactive and itis suitable to dilute them in a chemically inert substance. To this end,trichlorofluoromethane may be used which will serve at the same time asauxiliary foaming agent. This precaution is less necessary with the acidchlorides.

It should be noted that the action of the chlorine-containingderivatives is not limited to the indirect effect of their hydrolysis.In fact, the chlorine-containing derivatives strongly accelerate thedecomposition of the reaction initiators, which causes a rapid increasein the molecular weight and thus in the viscosity. In addition, theydirectly destroy the quinone type reaction inhibitors.

III.- Inert fillers

The carbonates which may advantageously by used are, above all, calciumcarbonate, magnesium carbonate and ammonium carbonate.

Fly ashes, "floating" ashes, bentonite, diatomite will be mentioned asfillers containing adsorbed H₂ O.

As fillers with fire-proofing effect, particular mention will be made ofhydrated alumina Al(OH)₃ and antimony trioxide Sb₂ O₃.

Finally, reinforcing fillers may be used which are formed of silica,hollow or solid glass spherules, glass fibrils.

The starting mixture being liquid, the inert mineral fillers may be usedin very high proportions, up to a total of 80% by weight, based on thefinal foamed product. The ratio of mineral fillers to organic substancesis, however, preferably between 30/70 and 55/45 if all the fillers usedare considered.

Action of the chlorine-containing derivatives

To test the influence of the chlorine-containing derivatives on thecross-linking speed of the unsaturated polyesters, the duration ofgelation is measured at 20° C. for a polymerisable mixture containingSYNOLITE FTP 1140 (Trademark of a product derived from ethyleneglycolpolymaleate-phthalate and methyl methacrylate, sold by Synres),methylethylketone peroxide as polymerisation initiator and cobaltoctoate at 5% as accelerator as well as phosphorus trichloride PCl₃,then the duration of gelation of the same mixture without PCl₃ ismeasured.

Two tests are effected each time with different proportions of initiatorand accelerator. The results are given in the following Table:

    ______________________________________                                                    Parts (by Weight)                                                               Test     Test    Test   Test                                                  No. 1    No. 2   No. 3  No. 4                                                 (compar- (inven- (compar-                                                                             (inven-                                 Components    ison)    tion)   ison)  tion)                                   ______________________________________                                        SYNOLITE FTP 1140                                                                           100      100     100    100                                     methylethylketone                                                             peroxide      1        0.6     0.8    0.8                                     5% cobalt octoate                                                                           0.5      --      0.03   0.03                                    phosphorus tri-                                                               chloride      --       0.2     --     0.17                                    duration of gelation                                                                        15 min.  4 min.  12 hrs.                                                                              20 min.                                 ______________________________________                                    

In the first series of tests (Nos 1 and 2), it is observed that theduration of gelation is reduced from 15 to 4 min. when PCl₃ is added,although no accelerator is then used.

In the second series (Nos 3 and 4), the quantity of accelerator has beenreduced to 0.03%. The duration of gelation, consequently, is decreasedto 12 hrs. In the absence of PCl₃, but is only 20 min. if PCl₃ is added.

Production of the foamed polyesters and characteristics:

For the preparation of the filled foamed unsaturated polyester products,a first mixture A comprising the polyester + cross-linking agent system,the initiators and accelerators and the fillers, is formed. A secondmixture B is formed with the or each chlorine-containing derivative insolution in a halogen hydrocarbon (trichlorofluoromethane,trichloroethylene, carbon tetrachloride), in a vinyl monomer such asstyrene or in a linear unsaturated polyester with low hydroxyl value, orin a mixture of at least two of these substances.

The two mixtures are mixed, with intimate homogenisation by a rapidstirring by means of a mechanical stirrer. The reaction starts at20°-25° C. and the temperature rapidly reaches 80° to 120° C., underatmospheric pressure.

EXAMPLE 1

An ethyleneglycol polymaleate phthalate, with an OH value of 180,diluted in 25% styrene based on the polyester is used as the unsaturatedpolyester. The liquid system has a viscosity of 300 cPs.

    ______________________________________                                        Mixture A                                                                     Polyester/styrene system 1000 g                                               Benzoyl peroxide         8 g                                                  Methylethylketone peroxide                                                                             2 g                                                  Dimethylparatoluidine    2 g                                                  Magnesium carbonate      40 g                                                 Antimony bioxide         200 g                                                Hydrated alumina         500 g                                                Bentonite                250 g                                                Mixture B                                                                     Phosphorus trichloride   10 g                                                 Trichlorofluoromethane   50 g                                                 ______________________________________                                    

Polymerisation effected as indicated hereinabove.

The foaming step is completed in a few minutes. The foamed productobtainedhas a density of 300 kg/m³ (ratio of mineral fillers/organicsubstances in the product: about 50/50).

Its compressive strength is 40 kg/cm² and its tridimensional heatstability lies between 150° and 200° C.

(The tridimensional heat stability may be defined as the duration oflife in the furnace. To measure it, a sample of 20×20×4 cm is placededgewise in a drier at 100° C. The temperature is raised at the rate of10° C. per hour and the possible deformations are observed (shrinking,swelling, etc..) are noted. A stable material does not present anydeformation).

The final products present, in addition, the following characteristics.

Thermal insulation coefficient λ0.032 kcal/m/hr/°C. (according to Frenchstandard NF X 10021)

    ______________________________________                                        Average acoustic attenuation                                                  low-Pitched               30                                                  average                   65                                                  high pitched              75                                                  Bacteria resistance                                                           no development after 2 months.                                                ______________________________________                                    

The fire resistance of the foamed product obtained is evaluatedaccording to two different methods.

(a) Fire resistance: A sample is subjected to the action of anelectrical resistor of 500 watts for at least 20 min. The observationscorrespond to class M1 according to French standard NFP 92 507.Moreover, no piercing isobserved.

(b) Burning test of mines. A sample of a density of 300 kg/m³ exposed tothe flame of a propane blow pipe does not present any piercing after 2hours of exposure. After 1 hour, the temperature measured on the faceremote from the face exposed to the flame is only 90° C. This face thenpresents no browning. With a sample of a density of 500 kg/m³, nopiercing is observed after 5 hours of exposure to the flame.

EXAMPLE 2

The same polyester/styrene system as in Example 1 is used.

    ______________________________________                                        Mixture A                                                                     Polyester/styrene system 1000 g                                               Benzoyl peroxide         7 g                                                  Methylethylketone peroxide                                                                             2 g                                                  Dimethylparatoluidine    5 g                                                  Calcium carbonate        60 g                                                 Antimony trioxide        200 g                                                Hydrated alumina         1000 g                                               Mixture B                                                                     Acetyl chloride          30 g                                                 ______________________________________                                    

Cross-linking and foaming occur under the same conditions as in Example1.

The cellular product obtained has a density of 400 kg/m³ (ratio ofmineral fillers/organic substances in the product: about 55/45) and acompressive strength of 90 kg/cm². Other characteristics

    ______________________________________                                        Heat stability      180° C.                                            Heat insulation coefficient λ                                                              0.035 kcal/m/hr./°C.                               Fire resistance     as in Example 1                                           ______________________________________                                    

In Examples 3 to 7 hereinafter, only the compositions of the startingmixtures A and B are indicated. The operating mode is the same as inExamples 1 and 2.

EXAMPLE 3

    ______________________________________                                        Mixture A                                                                     STRATYL 515 R-P (polyester/styrene system                                     sold by Rhone-Poulenc)       100 g                                            Benzoyl peroxide             3 g                                              Methylethylketone peroxide   0.4 g                                            Paratoluidine                0.3 g                                            Cobalt octoate at 5%         0.4 g                                            Magnesium carbonate          20 g                                             Water                        1 g                                              Diatomite silica             50 g                                             Mixture B                                                                     Monomer styrene              20 g                                             Phosphorus trichloride       2 g                                              ______________________________________                                    

EXAMPLE 4

    ______________________________________                                        Mixture A                                                                     SYNOLITE 1574 VG (Trademark of a                                              polymaleate sold by Synres,                                                   Netherlands, with an OH value                                                 of 237)                    100 g                                              Diisocyanate               10 g                                               Benzoyl peroxide           3 g                                                Tert-butyl per-2-ethylhexoate                                                                            1.5 g                                              Paratoluidine              0.4 g                                              Magnesium carbonate        10 g                                               Fly ashes                  50 g                                               Antimony trioxide          10 g                                               hydrated alumina           100 g                                              Mixture B                                                                     Polyester with a OH value lower                                               than 30                    80 g                                               Styrene                    20 g                                               Phosphorus trichloride     2 g                                                Silicon tetrachloride      2 g                                                ______________________________________                                    

EXAMPLE 5

    ______________________________________                                        Mixture A                                                                     Uceflex 1 32 A (produced by                                                   Union Chimique Belge)   100 g                                                 Benzoyl peroxide        3 g                                                   tert-butyl per-2-hexoate                                                                              1.5 g                                                 Paratoluidine           0.6 g                                                 Calcium carbonate       20 g                                                  Bentonite               100 g                                                 Glass spherules         100 g                                                 Mixture B                                                                     Trichlorofluoromethane  20 g                                                  Phosphorus trichloride  2 g                                                   Silicon tetrachloride   2 g                                                   ______________________________________                                    

EXAMPLE 6

    ______________________________________                                        Mixture A                                                                     Hetron (polyester produced by                                                 Hooker Chemical Company, formed                                               by reacting a glycol with a                                                   chlorinated unsaturated diacid                                                itself deriving from hexa-                                                    chlorocyclopentadiene and                                                     phtalic anhydride)      100 g                                                 Styrene                 10 g                                                  Benzoyl peroxide        3 g                                                   Tert-butyl per-2-hexoate                                                                              3 g                                                   Dimethylparatoluidine   0.3 g                                                 Glycol                  10 g                                                  Hollow glass spherules  20 g                                                  Mixture B                                                                     Trichlorofluoromethane  20 g                                                  Phosphorus oxychloride  10 g                                                  ______________________________________                                    

EXAMPLE 7

    ______________________________________                                        Mixture A                                                                     SYNOLITE 892 (sold by Synres,                                                 Netherlands)            100 g                                                 Benzoyl peroxide        3 g                                                   Methylethylketone peroxide                                                                            0.3 g                                                 Paratoluidine           0.3 g                                                 Calcium carbonate       30 g                                                  Alumina                 120 g                                                 Mixture B                                                                     Styrene                 10 g                                                  Trichlorofluoromethane  20 g                                                  Phosphorus petachloride 3 g                                                   ______________________________________                                    

I claim:
 1. A method of producing a cured foamed product from a solutionof a linear unsaturated polyester in a cross-linking agent, said methodcomprising the step of contacting a reaction medium comprising saidsolution and a free radical initiator and containing free hydroxylradicals at room temperature and under atmospheric pressure, with atleast one foaming agent and with at least one totally hydrolyzablechlorine-containing derivative in an amount from 1 to 10% by weight,based on said solution, said chlorine-containing derivative comprisingat least one member selected from the group consisting of phosphorouschloride, phosphorous oxychloride, silicon chloride, and an acidchloride selected from acetyl chloride and benzoyl chloride, wherebysaid method produces said cured foamed product in a one-stage processwithout the external application of heat.
 2. A method according to claim1, wherein said reaction medium contains at least one inert mineralfiller.
 3. A method according to claim 2, wherein said inert mineralfiller comprises finely divided carbonate.
 4. A method of producing acured foamed product from a solution of a linear unsaturated polyesterin a cross-linking agent, comprising the step of contacting, at roomtemperature and under atmospheric pressure, a reaction medium comprisingsaid solution, a finely-divided carbonate filler, and a free radicalinitiator, and containing free hydroxyl radicals with at least onetotally hydrolyzable chlorine-containing derivative in an amount of from1 to 10% by weight, based on said solution, said chlorine-containingderivative being selected from the group consisting of phosphorouschloride, phosphorous oxychloride, silicon chloride, and an acidchloride selected from the group consisting of acetyl chloride andbenzoyl chloride whereby said cured foamed product is produced in aone-stage process without external application of heat, and wherebyfoaming occurs by virtue of the in situ generation of carbon dioxide gasfrom the reaction of said filler with the hydrolysis product of saidchlorine-containing derivative.
 5. A method according to claim 3 or 4,wherein said carbonate comprises at least one of magnesium carbonate,calcium carbonate and ammonium carbonate.
 6. A method according to claim2 or 4, wherein the ratio of said inert mineral filler to non-fillerorganic material is between 30/70 and 55/45 by weight.
 7. A methodaccording to claim 1 or 4, wherein the chlorine-containing derivative isadded to the reaction medium in admixture with a liquid foaming agent.